System and method for reinforcing reciprocating pump

ABSTRACT

A drive system for a fluid end of a reciprocating pump assembly including a drive member and a power end housing having a crankshaft rotatably disposed therein. The assembly includes a gearbox secured to the power end housing, the gearbox operatively connecting the drive member to the crankshaft for rotation thereof. The assembly further includes at least one arm member extending between the gearbox and the power end housing, the at least one arm member positioned to resist relative movement between the gearbox and the power end housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/155,793, filed May 1, 2015, U.S. Provisional Patent ApplicationNo. 62/095,689, filed Dec. 22, 2014, and U.S. Provisional ApplicationNo. 62/029,271, filed Jul. 25, 2014, each of which are incorporated byreference in their entireties.

TECHNICAL FIELD

This disclosure relates to a reciprocating pump assembly, and inparticular, a power end housing for a reciprocating pump assembly.

BACKGROUND OF THE DISCLOSURE

In oil field operations, reciprocating pumps are used for variouspurposes. For example, reciprocating pumps are commonly used foroperations, such as cementing, acidizing, or fracing a well. Oftentimes,these reciprocating pumps are mounted to a truck, a skid or other typeof platform for transport to and from the well sites. In operation, suchpumps deliver a fluid or slurry at pressures up to and around 20,000psi; however, due to such extreme operating conditions, these pumps aresusceptible to damage from forces caused by excessive vibrations,bending moments and/or deformation.

A typical reciprocating pump includes a fluid end and a power end, thepower end configured to reciprocatingly move one or more plungers towardand away from a corresponding fluid end pump chamber. Each chamberincludes an intake port for receiving fluid, a discharge port fordischarging the pressurized fluid, and a one-way flow valve in each portfor preventing reverse fluid flow.

Manufacturing and assembling conventional power end housings isoftentimes difficult and cumbersome due to, for example, the sheerweight of the housing, the need for precise alignment certaincomponents, and the difficultly in accessing certain areas of thehousing, such as, for example, accessing and installing the crankshaftbearings within the housing.

Thus, there is a need for a pump design, and in particular, a power endhousing for a reciprocating pump, having a decreased weight, that can beeasily assembled while at the same time able to reduce the likelihood ofdamage due to excessive forces caused by excessive vibrations, bendingmoments and/or deformation.

SUMMARY

In a first aspect, there is provided a drive system for a fluid end of areciprocating pump assembly, the drive system including a drive member;a power end housing having a crankshaft rotatably disposed therein; agearbox secured to the power end housing, the gearbox operativelyconnecting the drive member to the crankshaft for rotation thereof; andat least one arm member extending between the gearbox and the power endhousing, the at least one arm member positioned to resist relativemovement between the gearbox and the power end housing.

In certain embodiments, the at least one arm member includes at leasttwo arm members extending between the gearbox and the power end housingto resist relative movement between the gearbox and the power endhousing.

In other certain embodiments, the at least two arm members are parallelwith respect to each other.

In some embodiments, the at least one arm member includes at least twoarm members extending between the gearbox and the power end housing on asame plane.

In other embodiments, the at least one arm member includes an adjustablelength.

In still other embodiments, the at least one arm member is pivotablysecured to the power end housing.

In another embodiment, the at least one arm member is pivotably securedto the gearbox.

In still another embodiment, the power end housing is formed having afront wall, a rear wall, a top wall and a bottom wall, the at least onearm member coupled to the power end housing adjacent the front wall.

In yet another embodiment, the at least one arm member is pivotablysecured to the power end housing adjacent the top wall.

In a second aspect, there is provided a method of assembling a drivesystem for a fluid end of a reciprocating pump assembly, the methodincluding providing a drive member; providing a power end housing havinga crankshaft rotatably disposed therein; securing a gearbox to the powerend housing so as to operatively connect the drive member to thecrankshaft for rotation thereof; and securing at least one arm memberbetween the power end housing and the gearbox to resist relativemovement between the gearbox and the power end housing.

In some embodiments, securing the at last one arm member between thepower end housing and the gearbox includes securing at least two armmembers between the gearbox and the power end housing.

In other embodiments, securing the at least one arm member includessecuring at least two arm members between the gearbox and the power endhousing in a parallel relationship.

In certain embodiments, the method includes securing the at least twoarm members between the gearbox and the power end housing in a sameplane.

In another embodiment, the method includes adjusting a length of the atleast one arm member to extend between the gearbox and the power endhousing.

In yet another embodiment, the method includes pivotably securing an endof the at least one arm member to the power end housing.

In some embodiments, the method includes pivotably securing an end ofthe at least one arm member to the gearbox.

In other embodiments, the method includes securing the at least one armmember adjacent to a front wall of the power end housing.

In yet other embodiments, the method includes securing the at least onearm member adjacent to a top wall of the power end housing.

In still other embodiments, the method includes securing an end of theat least one arm member to a skid that supports the power end housing.

In a third aspect, there is provided a method of attaching an arm memberto a drive system for a fluid end of a reciprocating pump assembly, themethod including forming a counterbore in a power end housing, thecounterbore having a first section with a diameter and a second sectionwith a diameter different from the diameter of the first section;providing a bolt, the bolt including a first section having a diametercorresponding to the diameter of the counterbore first section, and asecond threaded section having a diameter corresponding to the diameterof the counterbore second section, the second section of the boltthreadably engaging the counterbore second section; and the diameter ofthe first section of the bolt having a larger diameter than the diameterof the second section of the bolt such that, when the first section ofthe bolt engages the counterbore first section, the first section of thebolt substantially absorbs shear forces during operation of thereciprocating pump assembly.

In some embodiments, forming the counterbore first section includesforming a diameter of the counterbore first section to provide aclearance of about 0.002 inches between the counterbore and the bolt.

Other aspects, features, and advantages will become apparent from thefollowing detailed description when taken in conjunction with theaccompanying drawings, which are part of this disclosure and whichillustrate, by way of example, principles of the inventions disclosed.

DESCRIPTION OF THE FIGURES

The accompanying drawings facilitate an understanding of the variousembodiments.

FIG. 1 is an illustration of a reciprocating pump assembly having apower end housing and a fluid end housing.

FIG. 2A is a top perspective view of a frame assembly of the power endhousing of FIG. 1.

FIG. 2B is a bottom perspective view of the frame assembly of FIG. 2B.

FIG. 3 is front perspective view of a middle plate segment of the frameassembly of FIGS. 2A and 2B.

FIG. 4 is a partial exploded front perspective view of a plurality ofthe middle plate segments of FIG. 3 having a plurality of crossheadsupport bars.

FIG. 5 is a section view of a portion of the frame assembly of FIG. 4taken along the line 5-5.

FIG. 6 is a perspective view of the crosshead support bar.

FIG. 7 is a front perspective view of an endplate segment of the frameassembly of FIGS. 2A and 2B.

FIG. 8 is rear perspective view of a portion of the frame assembly ofFIGS. 2A and 2B in which a plurality of rear support bars are securedthereto.

FIG. 9 is a partial exploded front perspective view of a portion of theframe assembly of FIGS. 2A and 2B with a plurality of crosshead supporttubes supported therein.

FIG. 10A is a top perspective view of a top skin assembly.

FIG. 10B is a bottom perspective view of a portion of a bottom skinassembly.

FIG. 10C is a perspective view of another portion of the bottom skinassembly.

FIG. 10D is a front perspective view of upper and lower nose plates.

FIG. 11 is a block diagram illustrating assembly of the frame assemblyof FIGS. 2A and 2B.

FIG. 12 is a front perspective view of another embodiment of a frameassembly in which a plurality of forged segments having extensionmembers extending therefrom are employed to advantage.

FIG. 13 is a rear view of the frame assembly of FIG. 12.

FIG. 14 is a perspective view of an end plate segment of the frameassembly of FIGS. 12 and 13.

FIG. 15 is a perspective view of a middle plate segment of the frameassembly of FIGS. 12 and 13.

FIG. 16 is a perspective view of another embodiment of a middle platesegment.

FIG. 17 is a perspective view of yet another embodiment of a middleplate segment.

FIGS. 18A and 18B are perspective views of another embodiment of leftand right end plate segments.

FIG. 19 is a perspective view of another embodiment of a middle platesegment.

FIG. 20 is a front perspective view of two adjacently positioned middleplate segments illustrated in FIG. 19.

FIGS. 21-23 are simplified section views of the frame assembly of FIG.29 taken along the line 21-21.

FIGS. 24-26 are simplified section views of a crankshaft illustratingbearing races being installed onto the crankshaft.

FIGS. 27 and 28 are simplified section views of the crankshaft beinginserted into the frame assembly of FIGS. 40 and 41.

FIG. 29 is a rear perspective view of another embodiment of a frameassembly in which the end plate segments and middle plate segments arepartially cut-away.

FIGS. 30-38 are illustrations of the frame assembly of FIG. 29 showingthe bearing races being installed onto the bearing support surfaces.

FIG. 39 is an illustration of a crankshaft support member for liftingand supporting a crankshaft during installation onto and removal fromthe power end housing.

FIGS. 40-42 are illustrations of the crankshaft support membersupporting the crankshaft during installation of the crankshaft onto thepower end housing.

FIG. 43 is an illustration of the crankshaft support member detachedfrom the crankshaft after installation of the crankshaft onto the powerend housing.

FIGS. 44-47 illustrate the installation of the outer bearing assembliesto support the crankshaft on the power end housing.

FIG. 48 is a front perspective view of a portion of a gearbox coupled toan end plate segment of a frame assembly.

FIG. 49 is a front view of the gearbox and end plate segment of FIG. 48.

FIG. 50 is a top view of the gearbox and end plate segment of FIGS. 48and 49.

FIG. 51 is a perspective view of an arm member illustrated in FIGS.48-50.

FIG. 52 is a side view of the arm member of FIG. 51.

FIG. 53 is a section view of the arm member of FIG. 51 taken along theline 53-53 of FIG. 52.

FIG. 54 is a section view of a portion of the frame assembly of FIG.48-5 taken along the line of 54-54 of FIG. 24.

FIG. 55 is a front view of a gearbox and end plate segment of FIG. 48illustrating an arm member secured to a trailer/skid.

FIG. 56 is an illustration of the power end housing of FIG. 1 secured toa skid.

FIG. 57 is a top perspective view of the skid illustrated in FIG. 55.

FIGS. 58 and 59 are illustrations of an alternate skid arrangement.

FIG. 60 is a simplified illustration of the skid of FIGS. 58 and 59secured to a trailer.

FIG. 61 is an exploded cross sectional view of a portion of a middleplate segment of FIG. 19 and a portion of the bottom skin assembly ofFIG. 10B.

FIG. 62 is a cross sectional view of the bottom skin and middle platesegment of FIG. 61 welded together.

DETAILED DESCRIPTION

FIG. 1 is an illustration of a reciprocating pump assembly 10, such as,for example, a reciprocating plunger pump. Reciprocating pumps can beused, for example, as frac pumps, mud pumps, cement pumps, and the like.Terminology may be used in this disclosure that is commonly used in agiven pump system; however, unless otherwise stated, this disclosurealso includes comparable components of other pump systems (e.g.,crossheads and pistons). Referring to FIG. 1, the pump assembly 10includes a power end housing 12 coupled to a fluid end housing 14 via aplurality of stay rods 20. The power end housing 12 includes acrankshaft 16 depicted, for example, in FIG. 40), which is mechanicallyconnected to a motor (not shown), which in operation, rotates thecrankshaft 16 in order to drive the reciprocating pump assembly 10. Inparticular, rotation of the crankshaft 16 causes a plunger assembly 18to reciprocate toward and away from the fluid end housing 14, whichcauses fluid to be pumped from one or more fluid cylinders (notillustrated) in the fluid end housing 14 through a discharge port 24. Inone embodiment, the crankshaft 16 is cammed so that fluid is pumped froma plurality of cylinders in the fluid end housing 14 to minimize theprimary, secondary and tertiary forces associated with reciprocatingpumps 10. According to embodiments disclosed herein, the power endhousing 14 employs a frame assembly 40 (FIGS. 2A and 2B), which providesfor increased structural rigidity (i.e., increased resistance todeformation and/or deflection) and ease of assembly.

In the embodiment illustrated in FIGS. 2A and 2B, the frame assembly 40includes a pair of end segments 42 and 44, a plurality of middlesegments 46, a top skin assembly 48 and a bottom skin assembly 50forming a forward or front wall 54, a rear or back wall 56, and a pairof sidewalls 58 and 60. In the embodiment illustrated in FIGS. 2A and2B, for example, the frame assembly 40 includes four equally spacedapart middle segments 46 disposed between the end segments 42 and 44 toaccommodate, as discussed in further detail below, five plungerassemblies 18 thereby forming a quintuplex pump assembly. However, itshould be understood the frame assembly 40 is otherwise configurable.For example, the frame assembly 40 is configurable to accommodate aduplex pump assembly, which can include at least one middle segment 46disposed between the end segments 42 and 44. Likewise, the frameassembly 40 is configurable to accommodate a triplex pump assembly,which includes two spaced apart middle segments 46 disposed between theend segments 42 and 44. According to some embodiments, each of thesegments 42, 44 and 46 are laterally spaced apart approximately twelveinches, although depending on the size of the pump assembly 10, thelateral spacing may be a longer or shorter distance. In yet otherembodiments, the lateral spacing is not equal for the middle segments46. In other embodiments, the frame assembly 40 is configured to includeat least one segment 42 or 44. In still other embodiments, the frameassembly 40 includes at least one segment 42 or 44 and does not includethe middle segments 46.

In the embodiment illustrated in FIGS. 2A and 2B, the frame assembly 40includes a plurality of feet 52, which, as discussed in greater detailbelow, are configured to support the power end housing 12 on a supportsurface, such as, for example, a skid, a truck bed, trailer or othertype of platform. In FIG. 2B, for example, each end segment 42 and 44includes a foot 52 near or adjacent to the forward wall 54 and a foot 52near or adjacent the rear wall 56. Furthermore, in the embodimentillustrated in FIG. 2B, each middle segment 46 includes a foot 52extending near or adjacent to the rear wall 56. It should be understood,however, that the number, size and position of each foot 52 is variabledepending on the desired configuration. For example, in someembodiments, an end segment 42 or 44 includes a single foot 52 extendingentirely or at least partially between the front and rear walls 54 and56. In some embodiments, one or more additional feet 52 are otherwisepositionable between the feet 52 that are located near or adjacent tothe front and rear walls 54 and 56. Thus, for example, in oneembodiment, an end segment 42 or 44 includes three, four or even morespaced apart feet 52 for supporting the power end housing 12. In theembodiment illustrated in FIGS. 2B, the feet 52 are integrally formed onsegments 42, 44 and 46; however, it should be understood that in otherembodiments, the feet 52 are separately attachable to the segments 42,44 and/or 46.

With continued reference to FIG. 2B, each middle segment 46 includes asingle foot 52 generally near or adjacent to the rear wall 56. Inalternate embodiments, each middle segment 46 includes additional feet52. For example, in some embodiments, a middle segment 46 includes afoot 52 (not illustrated) at or near the front wall 54 or at any otherposition between the front and rear wall 54 or 56 in addition to thefoot 52 at or near the rear wall 56. In the embodiment illustrated inFIG. 2B, for example, a total of eight feet 52 are used to support thepower end housing 14 on a support surface (not illustrated). As will bediscussed in greater detail below, the provision of additional feet 52on the frame assembly 40, and in particular, feet 52 on middle segments46, provide an increased stiffness resulting in less deflection and/ordeformation of the frame assembly 40 during operation the reciprocatingpump 10 thereby increasing the operating life of certain components,such as, for example, the bearings utilized to support the crankshaft16.

Referring now to FIGS. 3-5, the middle segments 46 of FIGS. 2A and 2Bare illustrated. In FIG. 3, for example, each middle segment 46 includesupper and lower grooves 80 and 82 and a bearing support surface 84.Upper and lower grooves 80 and 82 are positioned and otherwise sized soas to receive corresponding upper and lower crosshead support members 86and 88 (FIG. 4) that, as explained in greater detail below, providesupport for crosshead support tubes 100 (FIG. 9) and a means for moreeasily aligning and otherwise spacing apart the segments 42, 44 and 46.Furthermore, upper and lower support members 86 and 88 providestructural support to the segments 42, 44 and 46, and thus, the frameassembly 40. For example, referring specifically to FIGS. 3-6, eachmiddle segment 46 is positioned such that the upper and lower grooves 80and 82 are aligned to receive respective portions of the upper and lowercrosshead support members 86 and 88. When secured together, thecrosshead support members 86 and 88 provide additional rigidity to andmaintain alignment of the segments 42, 44 and 46 and, thus, the frameassembly 40.

Referring specifically to FIG. 6, the crosshead support members 86 and88 are rigid rod-like members and are sized to extend through each ofthe middle segments 46 and attached to the end segments 42 and 44 (FIG.9). In FIG. 6, the crosshead support members 86 and 88 are formed havinga top surface 90, a bottom surface 92 and end surfaces 94 and 96. In theembodiment illustrated in FIG. 6, the top surface 90 includes aplurality of spaced apart recessed surfaces 98, each configured toreceive and otherwise support at least a portion of a crosshead tube 100(FIGS. 2A, 2B and 9) therein. Thus, for example, when the upper andlower crosshead support members 86 and 88 are positioned within theupper and lower grooves 80 and 82, respectively, the crosshead tubes 100fit within and are supported by the recessed surfaces 98 in the upperand lower support members 86 and 88.

In the embodiment illustrated in FIG. 6, the recessed surfaces 98 arearcuately shaped and sized to receive and otherwise conform to the outersurface of the crosshead tubes 100. It should be understood, however,that the recessed surfaces 98 can be otherwise configured. For example,in some embodiments, the recessed surfaces 98 include non-arcuatelyformed notches or recessed areas. In other embodiments, spaced apartextension members (not illustrated) extend outward from the top surface90 of the support members 86 and 88, the extension members being spacedapart a sufficient distance to receive and otherwise support thecrosshead tube 100 therebetween to prevent movement of the crossheadtube 100 relative to the crosshead support member 86, 88.

With continued referenced to FIG. 6, each crosshead support member 86,88 includes a support segment 102 extending between each of the recessedsurfaces 98. The support segments 102 are configured to facilitatealignment and attachment of the support members 86, 88 to the segments42, 44 and 46. In the embodiment illustrated in FIG. 6, for example, thebottom surface 92 of the support segments 102 includes an alignmentnotch or recessed portion 104 positioned to receive and otherwise engagethe middle segments 46. Referring specifically to FIGS. 4 and 5, forexample, the notches 104 on the upper and lower support members 86 and88 are formed along the bottom surfaces 92 such that upon attachment ofthe support members 86 and 88 to the middle segments 46, such notches104 are aligned with and are configured to conform and/or otherwiseinterlock with the segments 46.

In the embodiment illustrated in FIG. 4, the frame assembly 40 includestwo upper crosshead support members 86 and two lower crosshead supportmembers 88. For example, in FIGS. 3 and 4, each middle segment 46includes a pair of parallel upper grooves 80 and a pair of parallel andcorresponding lower grooves 82 to accommodate a front or first pair ofcrosshead tube support members 106 and a rear or second pair ofcrosshead support members 108. In other embodiments, additional pairs ofcrosshead support members 86 and 88 are utilized, such as, for example,a third pair (not illustrated) of crosshead support members 86 and 88disposed between the first and second crosshead support members 106 and108. Furthermore, in alternate embodiments, a single pair of crossheadsupport member 86 and 88 is utilized. Notwithstanding the number and/orposition of the crosshead support members 86 and 88, the crossheadsupport members 86 and 88 assist in alignment of segments 42, 44 and 46,provide additional support and structural rigidity to the frame assembly40, both during assembly and operation of the reciprocating pumpassembly 10, and provide a means to support the crosshead tubes 100within the frame assembly 40.

Referring now to FIG. 7, the end segment 44 is illustrated. Similar tothe middle segments 46, the end segment 44 includes a bearing supportsurface 84 and upper and lower grooves 80 and 82 configured to receiveand otherwise mate with notches 104 adjacent the end surfaces 96 on thecrosshead support members 86 and 88 (FIG. 6). While only end segment 44is illustrated, it should be understood that end segment 42 contains asimilar configuration for attachment to crosshead support members 86 and88 at the opposite end surfaces 94.

Referring specifically to FIGS. 3-5 and 7, the bearing support surfaces84 form arcuately extending openings 110 extending through each of theend and middle segments 42, 44 and 46. As discussed in further detailbelow, the bearing support surfaces 84 are sized to receive a bearingassembly 290 (See FIGS. 21-38 and 40-46), which facilitate therotational movement of the crankshaft 16 (FIG. 40). As will be discussedin greater detail below, the openings 110 formed by the bearing supportsurfaces 84 vary in size to facilitate the assembly of bearingassemblies 290 on respective segments 42, 44 and/or 46.

In FIGS. 3, 7 and 8, the rear walls 56 of the end and middle segments42, 44 and 46 include upper and lower grooves 140 and 142. When themiddle segments 46 are positioned and aligned between the end segments42 and 44, as illustrated, for example, in FIG. 8, an upper rod member144 and a lower rod member 146 are disposed therein to provideadditional support and rigidity to frame assembly 40. In the embodimentillustrated in FIG. 8, two rod members 144 and 146 are illustrated.However, in other embodiments, a greater or fewer number of rod members144 and 146 can be utilized. In yet other embodiments, the rod members144 and 146 extend only a partial distance between the end segments 42and 44. In other embodiments, the rod members 144 and 146 are configuredin a position other than horizontally. For example, in some embodiments,the rod members 144 and/or 146 are angularly disposed along the rearwall 56 of the frame assembly 40. According to some embodiments, the rodmembers 144 and 146 each include spaced apart alignment notchesconfigured to correspond to and otherwise engage with the rear wall 56of the frame assembly 40. Such notches provide for ease of assembly andenable self-alignment of the segments 42, 44 and/or 46 during assembly.

Referring to FIG. 9, once the crosshead support members 86 and 88 aresecured to the frame assembly 40, and in particular, to the segments 42,44 and 46, the crosshead tubes 100 are secured between crosshead supportmembers 86 and 88 and are positioned generally adjacent to the frontwall 54 of the frame assembly 40. Once the crosshead tubes 100 aresecured thereto, the top skin assembly 48, as best illustrated in FIG.10A, is secured to the frame assembly 40. In the embodiment illustratedin FIG. 10A, the top skin assembly 48 includes a front plate 160 and arear curvilinear plate 162, which together are sized to cover andotherwise enclose the top portion of the power end housing 12 betweenthe segments 42, 44 and/or 46 by extending from the front wall 54 to therear wall 56 of the frame assembly 40. However, in alternateembodiments, the top skin assembly 48 is a single unitary plateextending between or at least partially between the front and rear walls54 and 56. In the embodiment illustrated in FIGS. 2A and 10A, the topskin assembly 48 consists of a plurality of front and rear plates 160and 162 that are mounted between each of the segments 42, 44 and 46 toenclose the top portion of the power end housing 12. In otherembodiments, the top skin assembly 48, is formed of a single unitarysheet sized to overlay the upper or top portion of the frame assembly40, which extends between the front wall 54, the rear wall 56 and thesidewalls 58 and 60.

Referring to FIGS. 2B and FIGS. 10B and 10C, the bottom skin assembly 50is illustrated. The bottom skin assembly 50 includes a plurality offront plates 164 that are sized to fit between each of the segments 42,44 and 46 and extending rearward from the front wall 54. The bottom skinassembly 50 further includes a drain plate 166 that extends between theend segments 42 and 44, as best illustrated in FIG. 2B. The drain plate166 further includes a plurality of drain openings 168 aligned generallybeneath the middle segments 46. In other embodiments, the bottom skinassembly 50 is formed of a single unitary sheet sized to overlay thebottom portion of the frame assembly 40, which extends between the frontwall 54, the rear wall 56, and the sidewalls 58 and 60.

FIG. 10D illustrates upper and lower nose plates 170 and 172, which aresecured to the frame assembly 40 to form at least a portion of the frontwall 54, as best illustrated in FIG. 2A. In particular, an upper noseplate 170 is secured to the frame assembly 40, between segments 42, 44and 46, above each crosshead tube 100. Likewise, a lower nose plate 172is secured to the frame assembly 40, between segments 42, 44 and 46,below each crosshead tube 100.

Referring now to FIG. 11, a method of assembling the frame assembly 40is illustrated. The method begins at block 200 by providing at least onemiddle segment 46. For example, when assembling a quintuplex pump, fourmiddle segments 46 are provided. Likewise, when assembling a triplexpump, two middle segments 46 are provided. Continuing to block 204, themiddle segments 46 are positioned such that the upper and lower grooves80 and 82 on each segment 46 are aligned. Once aligned, the crossheadsupport members 86 and 88 are aligned with and inserted within the upperand lower grooves 80 and 82 of each middle segment 46, as indicated atblock 204. Once positioned within the grooves 80 and 82, the crossheadsupport members 86 and 88 are secured to the middle segments 46, asindicated at block 206. According to some embodiments, the crossheadsupport members 86 and 88 are tack welded to the middle segments 46;however, any other suitable means of attachment can be used. At block208, the end segments 42 and 44 are secured to the crosshead supportmembers 80 and 82 using similar methods of attachment.

The method continues at block 210, where at least one rear support rod144 or 146 is positioned along the rear wall 56 of the frame assembly.In particular, a rear support rod 144 is inserted within a groove 140disposed in each end segment 42 and 44 and each middle segment 46. Insome embodiments, both an upper and lower rear support rod 144 and 146are inserted into respective upper and lower grooves 140 and 142 on eachsegment 42, 44 and 46 for providing additional stability to the rearportion of the frame assembly 40. According to some embodiments, theupper and lower support rods 144 and 146 are tack welded to the middlesections 46. At block 212, the method optionally includes securing aplurality of gussets 22 (FIG. 2B) between each of the end segments 42,44 and middle segments 46, which provide additional stability to theframe assembly 40. At blocks 214 and 216, the top skin assembly 48 andthe bottom skin assembly 50 are secured to the frame assembly 40 bywelding or other means of attachment. Continuing on to block 218, thefeet 52 on each of the segments 42, 44 and 46 are machined such that theends of each of the feet 52 are aligned in the same plane, so that, asdiscussed in greater detail below, the frame assembly 40 is securable toa skid or other support surface. While FIG. 11 illustrates one methodfor assembling the frame assembly 40, it should be understood that themethod can occur in other orders. For example, the crosshead supportmembers 86 and 88 are securable to the end segments 42 and 44 prior tosecuring the cross support members 86 and 88 to the middle segments 46.In addition, the rear support members 140 and 142 are attachable to thesegments 42, 44 and 46 prior to attaching the crosshead support members86 and 88 to the segments 42, 44 and 46. Similarly, the bearing supportsurfaces 84 can be formed in the segments 42, 44 and/or 46 while securedto the skid.

Referring now to FIGS. 12-15, an additional embodiment of the frameassembly 40 of the power end housing 12 is illustrated. In theembodiment illustrated in FIGS. 12-15, the end segments 42 and 44 andmiddle segments 46 each include gussets or extensions 650 extending froma sidewall of and formed integral with each segment 42, 44 and 46 so asto provide additional strength and stability to the frame assembly 40.For example, referring specifically to FIGS. 14 and 15, each segment 44and 46 includes a plurality of extensions 650 formed integral with andextending outward from a sidewall and in spaced apart relationshiparound the bearing support surfaces 84. As illustrated in FIGS. 12 and13, each extension 650 on a middle segment 46 is positioned to alignwith and contact a corresponding extension 650 on an adjacentlypositioned end segment 42 or 44 or middle segment 46, as applicable.Additionally or alternatively, the front wall 54 of each segment 42, 44and/or 46 is formed of an increased width such that the use andinstallation of separately attachable upper and lower nose plates 170and 172 (FIGS. 2A and 2B) is not necessary. For example, as illustratedin FIGS. 16 and 17, the front wall 54 is formed integral with andextending from a sidewall of the segment 42, 44 and/or 46 such that whensegments 42, 44 and/or 46 are adjacently positioned to form the frameassembly 40, the edges 50 a and 50 b of adjacently positioned framemembers 42, 44 and/or 46 align and contact each other for subsequentwelding and/or other forms of attachment. Similarly, each segment 42, 44and/or 46 can optionally be formed with rear walls 56 integrally formedwith an increased width extending from the sidewall such that the useand installation of separately attachable members disposed between eachof the segments 42, 44 and/or 46 is avoided.

Additionally and/or alternatively, each of the segments 42, 44 and/or 46can be formed such that, in addition to the front and rear walls 54 and56 being formed integral with the segments 42, 44 and/or 46, the top andbottom skins 48 and 50 can be formed integral thereto, as bestillustrated in FIG. 17. Thus, when segments 42, 44 and/or 46 areadjacently positioned to form the frame assembly 40, the edges 48 a and48 b and 50 a and 50 b of the top and bottom skins 48 and 50,respectively, of adjacently positioned frame members 42, 44 and/or 46contact each other for subsequent welding, thereby avoiding the need forseparately attachable skins 48 and 50 to be welded between the segments42, 44 and/or 46.

According to embodiments disclosed herein, one or more of the segments42, 44 and/or 46 are forged, including extensions 650; however, othermethods of manufacture are available (i.e., casting or otherwise). Whensegments 42, 44 and/or 46 are forged, welding time is reduced and lessmachining is required. As such, this results in ease of manufacture,lower costs, and higher strength. According to some embodiments, thesegments 42, 44 and/or 46 are hot forged. According to some embodiments,the strength of the segments 42, 44 and/or 46 is increased by about10-15 percent from a machined segment. According to embodimentsdisclosed herein, the end segments 42 and 44 may be forged and themiddle segments may be machined. In other embodiments, only one endsegment 42 or 44 may be forged and all or a some of the middle platesegments 46 may be forged and the remaining segments 42, 44 and/or 46machined or otherwise formed.

Referring now to FIGS. 18A-20, an additional embodiment of portions ofthe frame assembly 40 of the power end housing 12 is illustrated. InFIGS. 18A, 18B and 19, a plurality of extensions 650 are disposedgenerally adjacent to the bearing support surfaces 84 on each of the endsegments 42 and 44 and the middle plate segment 46. As illustrated, fiveextensions 650 are spaced apart from each other and generally around thebearing support surface 84; however, it should be understood that agreater or fewer number of extensions 650 may be utilized around thebearing support surfaces 84. Additionally and as illustrated in FIGS.18A, 18B and 19, each plate segment 42, 44 and 46 include upper andlower extensions 652 extending outwardly therefrom and disposedgenerally between the front wall 54 and the bearing support surfaces 84.In addition to providing additional rigidity to the frame assembly 40,the extensions 652 are used to support the crosshead tubes 100 (FIG. 9).When the extensions 652 are utilized, as illustrated in FIGS. 18A-20,crosshead tube support members 86 and 88 (FIG. 4) are no longernecessary since the extensions 652 act to align and sufficiently spaceapart the segments 42, 44 and/or 46 while at the same time providingsupport to the crosshead tubes 100. In particular, each extension 652includes a curvilinear portion 654 sized to receive the cylindricalcrosshead tubes 100. As such, the amount of welds can be substantiallyreduced (i.e., no need to weld the crosshead tube support members 86 and88 to the frame assembly 40) because the only welding required is at thepoint of contact between adjacently positioned extension members 652. InFIGS. 18A-20, in addition to extensions 650 and 652 being used to alignand secure the segments 42, 44 and/or 46 together, the front wall 54 ofeach segment 42, 44 and/or 46 are sized and position to function in thisfashion.

A method of assembling the frame assembly 40 illustrated in FIGS. 18A-20is hereinafter described. During assembly, at least one middle segment46 is provided. For example, when assembling a quintuplex pump, fourmiddle segments 46 are provided. Likewise, when assembling a triplexpump, two middle segments 46 are provided. The end segments 42 and 44and the desired number of middle segments 46 are aligned such that theends of each extension 650, and edges of the front walls 54, rear walls56 and top and bottom walls 58 and 60, as applicable, are aligned andotherwise adjacent to each other for attachment by welding or otherwise.In the embodiment illustrated herein, the end of each extension 650includes a planar surface having chamfered corners to facilitate weldingattachment. By including extensions 650 that are integral with segments42, 44 and/or 46, only a single weld is necessary to connect theextensions 650 together, and thus adjacent segments 42, 44 and/or 46,rather than employing a single gusset 22 that must be welded to bothadjacent segments 42, 44 and/or 46.

FIGS. 21-46 illustrate an embodiment of a graduated frame assembly inwhich the frame assembly 40 includes bearing support surfaces 84 ofvarying diameters to facilitate ease of installation of bearingassemblies 290 (FIG. 28), as more fully described below. Referringspecifically to FIG. 21, which is a cross-section of the frame assembly40 taken along the line 21-21 of FIG. 29, each bearing support surface84 is configured to receive and otherwise support the bearing assembly290 (FIG. 28) to rotatably support the crankshaft 16 thereon. Asillustrated in FIG. 21, the diameter of each of the bearing supportsurfaces 84 increases from the innermost middle segments 46 outward tothe end segments 42 and 44. For example, in the embodiment illustratedin FIGS. 21 and 29, the frame assembly 40 includes four middle segments300, 302, 304 and 306 and end segments 308 and 310. Each segment 300-310includes a respective bearing support surface 312, 314, 316, 318, 320and 322 for supporting a respective bearing assembly 290 (FIG. 28). Asillustrated in FIGS. 21 and 29, the innermost bearing support surfaces314 and 316 on segments 302 and 304 are formed having inner diameterssmaller than the inner diameters of adjacently positioned bearingsupport surfaces 312 and 318 on segments 300 and 306, respectively, asrepresented by an amount of twice the distance T1 (FIG. 21). Similarly,the bearing support surfaces 312 and 318 on segments 300 and 306,respectively, are formed having diameters smaller than the innerdiameters of adjacently positioned bearing support surfaces 320 and 322on end segments 308 and 310, respectively, as represented, for example,by an amount of twice the distance of T2 (FIG. 21). According to someembodiments, the diameter of bearing support surfaces 314 and 316 isabout 25 inches, the diameter of bearing support surfaces 312 and 318 isabout 25.25 inches, and the diameter of bearing support surfaces 320 and322 is about 25.5 inches. It should be understood, however, that thediameters can vary depending on the size of the frame assembly 40. Forexample, in some embodiments, the diameters can range between 2 inchesto 35 inches or even larger amounts. Regardless of the size of the frameassembly 40, and as explained in greater detail below, thisconfiguration of varying or “graduated” diameters of the bearing supportsurfaces 84 enables installation of the bearing assemblies 290 to beunimpeded and simplified.

With continued reference to FIGS. 21 and 29-34, installation of theouter bearing races 324 and 326 onto the bearing support surfaces 314and 316 is described. As illustrated, the inner diameters of bearingsupport surfaces 312, 318, 320 and 322 are larger than the outerdiameter of the outer bearing races 324 and 326. For example, in oneembodiment, the outer diameter of the bearing races 324 and 326 is about25 inches. Thus, as the outer bearing races 324 and 326 are moved in thedirection of arrows 328 and 330 and through the openings 110 formed bybearing support surfaces 312, 318, 320 and 322, the relative sizedifferences of about 0.5 inches between the outer bearing races 324 and326 and the diameter of bearing support surfaces 320 and 322, and therelative size differences of about 0.25 inches between the outer bearingraces 324 and 326 and the diameter of bearing support surfaces 312 and318, enable unimpeded movement of the bearing races 324 and 326therethrough. In another embodiment, the inner diameters of at least onebearing support surface 312, 318, 320 and 322 is larger than the outerdiameter of at least one of the outer bearing races 324 and 326. Thus,when installing the bearing races 324 and 326 on bearing supportsurfaces 314 and 316, the bearing races 324 and 326 are inserted intothe frame assembly 40 in the direction of arrows 328 and 330,respectively, toward middle segments 302 and 304 and through bearingsupport surfaces 312, 318, 320 and 322 with adequate clearance tominimize and/or substantially reduce the likelihood of the outer bearingraces 324 and/or 326 contacting the bearing support surfaces 312, 318,320 and 322 thereby “trapping” a bearing race 324 and/or 326 in thewrong position and/or otherwise damaging the bearing races 324 or 326and/or the bearing support surfaces 312, 318, 320 and 322. In someembodiments, the outer bearing races 324 and 326 are substantiallycooled to cause the races 324 and 326 to shrink, thereby increasing thegaps between the races 324 and 326 and the support surfaces 312, 318,320 and 322. Once positioned on the bearing support surfaces 314 and316, the temperature of the races 324 and 326 increases allowing thebearing races 324 and 326 to thermally expand to create an interferencefit with the bearing support surfaces 314 and 316.

Once the outer bearing races 324 and 326 are installed on the bearingsupport surfaces 314 and 316 (FIGS. 22 and 34), the outer bearing races332 and 334 are then inserted into the frame assembly 40 in thedirection of arrows 328 and 330, as best illustrated in FIGS. 22 and35-38. Similar to the outer bearing races 324 and 326, the outerdiameter of bearing races 332 and 334 is smaller than inner diameter ofbearing support surfaces 320 and 322 to facilitate unimpeded movement ofthe bearing races 332 and 334 for positioning onto support surfaces 312and 318, respectively. According to some embodiments, the outer diameterof the bearing races 332 and 334 is about 0.25 inches smaller than theinner diameters of the bearing support surfaces 320 and 322. It shouldbe understood, however, that the outer diameter of the bearing races 332and 334 may vary. For example, in one embodiment, the outer diameter ofthe bearing races 332 and 334 may range between 30/1000 of an inch to300/1000 of an inch smaller than the inner diameters of the bearingsupport surfaces 320 and 322. In other embodiments, the outer diameterof at least one of the bearing races 332 and 334 is equal to or smallerthan 0.30 inches, 0.25 inches, 0.20 inches, 0.15 inches, or 0.10 inchessmaller than the inner diameters of the bearing support surfaces 320 and322. In some embodiments, similar variations in diameters can be seenbetween outer diameters of the bearing races 324 and 326 compared withthe outer diameters of bearing races 332 and 334.

Referring to FIG. 23, after the bearing races 324, 326, 332 and 334 areinstalled on the frame assembly 40. As discussed in greater detailbelow, the bearing races 324, 326, 332 and 334 are used to support thecrankshaft 16 on the frame assembly 40, as illustrated, for example, inFIGS. 28 and 41.

Referring now to FIGS. 24-26, assembly of the crankshaft 16 and innerbearing races 412 and 414 thereon is illustrated. In the embodimentillustrated in FIG. 24, for example, the crankshaft 16 includes aplurality of journals 400, 402, 404, 406, 408 and 410 that areconfigured to receive a plurality of bearing races 412 and 414 thereon.As illustrated in FIG. 24, journals 404 and 406 are formed having adiameter that is larger than the diameters of journals 402 and 408.Likewise, journals 402 and 408 are formed having a diameter that islarger than the diameter of journals 400 and 410. According to oneexemplary embodiment, the diameters of journals 402 and 408 are betweenabout 0.030 and 0.062 inches smaller than the diameter of the journals404 and 406, although it should be understood that the relative lengthsmay be either larger or smaller. In addition and according to anotherexemplary embodiment, the diameter of the journals 400 and 410 arebetween about 0.062 and 0.124 inches smaller than the diameter of thejournals 404 and 406, although it should be understood that the relativelengths may be either larger or smaller. Regardless of the diameter sizeof journals 400, 402, 404, 406, 408 and 410, the varying sized diametersprovide ease of installation and/or removal of crankshaft bearings fromthe crankshaft 16.

For example, when assembling the bearing assemblies 412-418 onto thecrankshaft 16, the inner bearing races 412 are first installed followedby the inner bearing races 414. As illustrated in FIGS. 24 and 25, forexample, an inner diameter of the inner bearing races 412 is larger thanthe outer diameters of journal surfaces 400, 402, 408 and 410, whichfacilitates unimpeded installation of the bearing races 412 onto thecrankshaft 16, and in particular, journals 404 and 406. In particular,the inner bearing races 412 are positioned adjacent to each end of thecrankshaft 16 and moved in the direction of arrows 328 and 330 towardjournals 404 and 406. Once the innermost bearing assemblies 412 aresecured onto the surfaces 404 and 406, a pair of inner bearing races 414are then positioned onto journals 402 and 408, as illustrated in FIG.26. The inner diameter of the inner bearing races 414 is larger than thediameter of journals 400 and 410 to facilitate unimpeded movement in thedirection of arrows 328 and 330 across the journals 400 and 410. Oncethe inner bearing races 412 and 414 are secured onto the crankshaft 16,the outer bearing components, which include bearing races 416 and 418,are then installed onto and around the journals 400 and 410, as bestillustrated in FIG. 26.

According to some embodiments disclosed herein, in addition to sizingthe components to have different non-interfering diameters, thecrankshaft 16 is optionally cooled to a predetermined temperature inorder to effectuate thermal cooling thereby causing the crankshaft tocontract in size. When cooled and in the contracted state, the innerbearing races 412, 414, 416 and 418 are positionable on the crankshaft16. As the temperature of the crankshaft 16 increases, the bearing races412, 414, 416 and 418 are secured to the crankshaft 16 by aninterference fit. According to other embodiments disclosed herein, innerbearing races 412, 414, 416 and 418 can be heated (e.g., such as byinduction heating) to a predetermined temperature thereby causing theinner bearing races 412, 414, 416 and 418 to increase in size. Innerbearings races 412, 414, 416 and 418 can then be positioned oncrankshaft 16 and secured thereto by an interference fit.

After the bearing races 412, 414, 416 and 418 are installed onto thecrankshaft 16 (FIGS. 26 and 40), the crankshaft 16 is secured inside theframe assembly 40. Referring specifically to FIGS. 27, 28, 40 and 41,for example, the crankshaft 16 is moved in the direction of arrow 328such that the inner bearing races 412 are aligned with and otherwiseengage outer bearing races 324 and 326, the inner bearing races 414 arealigned with and otherwise engage the outer bearing races 332 and 334,and the bearing race 418 is aligned with the opening 110 on the endsegment 44. According to some embodiments, the crankshaft 16 can beinstalled on the opposite side of the frame assembly 40 such that whenmoved in the direction opposite of arrow 328, the crankshaft 16 isinserted within the frame assembly 40.

Referring now to FIGS. 39-43, a crankshaft support device 700 isemployed for supporting the crankshaft 16 during installation andremoval thereof. In use, the crankshaft support device 700 is configuredto support the crankshaft 16 in a generally horizontal position asillustrated, for example, in FIG. 40, so as to facilitate alignment ofthe crankshaft 16 with the bearing support surfaces 84. As explainedabove, once aligned with the bearing support surfaces 84, the crankshaft16 is movable along a horizontal axis (lifted and supported via a craneor otherwise) in the direction of arrow 328 for insertion within theopenings 110 formed by the bearing support surfaces 84. Once oriented inthe desired position, the support device 700 is detached from thecrankshaft 16.

Referring specifically to FIG. 39, the support device 700 includes aframe assembly 702 having a first segment 704 oriented to extendsubstantially along the length of the crankshaft 16 and a second portion706 extending from the first portion 704. The frame assembly furtherincludes a base section 708, which as described in further detail below,is used to secure the crankshaft 16 to the support device 700. Asillustrated, the second portion 706 extends a predetermined distancefrom the first portion 704 so as to enable the crankshaft 16 to bespaced apart from the first portion 704 such that when inserting thecrankshaft inside the bearing support surfaces 84, the first portion 704does not contact any portion of the power end housing 12.

Referring to FIGS. 39 and 43, the base section 708 includes a cavity 710sized to correspond to and receive an end of the crankshaft 16 therein.As illustrated in FIGS. 43-44, the crankshaft end includes threadedopenings corresponding to openings 716 in the base section 708. Whensecuring the support device 700 to the crankshaft 16, the openings 716are aligned with corresponding openings in the end of the crankshaft 16and a pair of threaded screws 718 are inserted therethrough to securelyfasten the crankshaft 16 to the support device 700.

In the embodiment illustrated in FIGS. 39-43, the first section 704includes a pair of eyelets 720 for receiving and engaging with a hangingstructure, such as a chain 722, that extends from a crane or otherlifting structure (not illustrated). The eyelets 720 are positioned onthe first section 704 and the length of the chains 722 are sized so thatthe crankshaft 16, when secured to the support device 700, remainsgenerally horizontal and/or otherwise parallel with an axis extendingthrough the center of the openings 110 formed by the bearing supportsurfaces 84. According to some embodiments, the eyelets 720 have liftingshackles (not illustrated) inserted therein to secure the support device700 to the chains. One lifting shackle attaches to a single length chainand the second shackle attaches to an adjustable chain to provide tilingfreedom during installation. For example, the eyelet 720 that isfarthest from second portion 706 can be engaged with an adjustablehanging structure, such as chain 722, such that crankshaft 16 can bebalanced substantially horizontally (e.g., to facilitate alignment ofthe crankshaft 16 with the bearing support surfaces 84) by adjusting theadjustable hanging structure.

It should be understood that support structure 700 may be otherwiseconfigured. For example, the first section 704 may extend a distancelonger or shorter than the overall length of the crankshaft 16.Likewise, the length of the second section 706 may otherwise vary (i.e.,may be longer or shorter than that depicted in FIGS. 39-43) and mayextend in any direction other than perpendicularly from the firstsection 704. According to some embodiments, the support structure 700 isformed of metal, wherein the first section 704, the second section 706and the base section are welded together. It should be understood,however, that the support structure 700 may be otherwise formed from anon-metallic material and be, for example, a single contiguous structureformed without welding.

According to some embodiments and as best illustrated in FIGS. 28 and43-47, once the crankshaft 16 is installed in the power end 12, a pairof carrier members 420 and 422, which support bearing races 290 thereon,are installed onto the end segments 310 and 308, respectively, forsupporting the crankshaft 16 for rotatable movement thereof.

Referring now to FIGS. 48-50, a gearbox 600 is secured to the end plate44 of the frame assembly 40 via a pair arm members 602 to resistmovement of the gearbox 600 relative to the frame assembly 40. In FIGS.48-50, for example, two arm members 602 are illustrated; however, inother embodiments, a greater or fewer number of arm members 602 may beemployed. For example, according to some embodiments, three or more armmembers 602 are secured between the end plate 44 and the gearbox 600 toresist relative movement between the end plate 44 and the gearbox 600.In operation, the position of the arm members 602 are optimized in orderto resist rotational and axial movement to prevent and/or otherwiseeliminate damage to the frame 40 and/or gearbox 600, including the outerhousing and thus, the components therein.

In FIGS. 48-50, the first and second ends 604 and 606 of the arm members602 are secured to the end plate of gearbox 600 (e.g., at gusset 620)and end plate 44 of frame assembly 40 (e.g., at gusset 620),respectively, such that the arm members 602 extend in a parallelconfiguration and in the same plane (FIG. 50). In the embodimentillustrated in FIG. 48, the arm members 602 generally extend and areotherwise disposed in a vertical plane that is near and/or otherwiseadjacent to the front wall 54 of the frame assembly 40. However, inother embodiments, the arm members 602 may be otherwise configured toaccommodate a different size and/or center of gravity of the gearbox600, which varies depending on the size of the reciprocating pumpassembly 10. For example, the arm members 602 may be secured in anon-parallel fashion and/or extend in different planes. Furthermore, thearm members 602, instead of being positioned and secured near oradjacent to the front wall 54 of the frame assembly 40, may be securedat other positions, such as, for example, at any position between thefront wall 54 and the rear wall 56 of the frame assembly 40. Likewise,the arm members 602 are secured at any position along the gearbox 600 toresist rotational and/or axial movement of the gearbox 600 relative tothe frame assembly 40.

Referring to FIGS. 51-54, the arm member 602 includes an elongate body608 and ball joints 610 at the first and second ends 604 and 606 tofacilitate pivotable movement, as discussed further below, duringinstallation of and attachment of the arm members 602 to the gearbox 600and the frame assembly 40. Furthermore, in some embodiments, each armmember 602 is adjustable in length to accommodate different sizedconfigurations of the reciprocating pump assembly 10. Referring to FIG.53, for example, each ball joint 610 is movable relative to the elongatebody 608 via a pair of threaded adjustment bolts 612, such that, when itis desired to extend the length of the arm member 602, the elongate body608 is rotated relative to the bolts 612 on each end 604 and 606. Thus,for example, in the event it is desired to extend the length of an armmember 602, the body member 608 is rotated in the direction of arrow 614(FIG. 51), which in turn causes rotational movement of the body member608 with respect to the bolts 612 (FIG. 53) to extend the length of thearm member 602. Similarly, in the event it is desired to shorten thelength of an arm member 602, the body member is rotated in the directionopposite of arrow 614 to cause movement of the body member 608 withrespect to the bolts 612 to reduce the length of the arm member 602.Once the arm member 602 is at the desired length, a pair of nuts 616 aretightened so that they abut against the body 608 to prevent relativemovement of the adjustment bolts 612 relative to the elongate body 608.

While embodiments of the arm member 602 illustrated having adjustablebolts 612 on both sides of the elongate body 608, it should beunderstood that the arm member 602 may be otherwise configured. Forexample, in some embodiments, the arm member 602 is of a fixed lengthwithout the ability to be adjusted in length. In other embodiments, thearm member 602 includes only one end 604 or 606 that is adjustable inlength. Thus, for example, the arm member 602 includes only a singlethreaded bolt 612 being adjustable to lengthen or shorten the arm member602. In yet other embodiments, the arm member 602 includes telescopingportions (not illustrated) that slide and otherwise move in atelescoping relationship to adjust the length thereof. A cotter pin orany other locking device is usable to secure the telescoping segments toprevent separation and/or relative movement between the members duringoperation of the pump assembly 10.

In the embodiment illustrated in FIGS. 51-54, the arm members 602 aresecured to the pump assembly 10 and the gearbox 600 via a shoulder bolt618 disposed in each end 604 and 606. The shoulder bolts 618 secure theends of the support members 602 to respective gussets 620 on the powerend housing 12 and the gearbox 600 (FIG. 49).

Referring specifically to FIG. 54, each shoulder bolt 618 is sized tofit within a corresponding counterbore 622 formed in each gusset 620. Asillustrated in FIG. 54, each counterbore includes a first section 622 ahaving a first diameter and a second section 622 b having a seconddiameter. In FIG. 54, the first diameter is larger than the seconddiameter so as to, as discussed in further detail below, receivecorresponding portions of the shoulder bolt 618 therein to reducefailure of the shoulder bolt 618, which oftentimes occurs in response toshear stresses generated during operation of the reciprocating pumpassembly 10.

In the embodiment illustrated in FIG. 54, the shoulder bolt 618 includesa first portion 618 a having a first diameter and a second portion 618 bhaving a second diameter, the diameters of the first and second portions618 a and 618 b corresponding to the diameters of portions 622 a and 622b of the counterbore 622. The shoulder bolt 618 is secured within thecounterbore 622 via a threaded connection between portions 618 b and 622b of the shoulder bolt 618 and the counterbore 622, respectively.According to some embodiments, the first portion 622 a of thecounterbore 622 is precision machined to have a clearance between thefirst portion 618 a of the shoulder bolt 618 and the first portion 622 aof the counterbore 622 of about 0.002 inches. Accordingly, when a shearforce F acts on the shoulder bolt 618, a significant portion of theshear is absorbed or otherwise countered by the first portion 618 a ofthe shoulder bolt 618 rather than the threaded second portion 618 b ofthe shoulder bolt 618. It should be understood that the clearancebetween the first portion 618 a of the shoulder bolt 618 and the firstportion 622 a of the counterbore 622 may vary (i.e., the clearancetherebetween may be greater or less than 0.002 inches). By having alarger diameter first section 618 a larger than the second section 618b, the shear stresses acting on the threaded section 618 b are reducedthereby reducing the likelihood of failure of the connection between thearm member 602 and the frame assembly 40 and the gearbox 600.

During assembly of the reciprocating pump assembly 10, the gearbox 600is secured to the power end housing 12. Once secured, at least one armmember 602 is provided for attachment between the end segment 44 and thegearbox 600 to resist relative movement, including relative axial androtational movement, between the gearbox 600 and the power end housing12. According to some embodiments, the length of the arm member 602 isfirst adjusted to the necessary length so as to connect to both thepower end housing 12 and the gearbox 600. Once positioned to the desiredlength, the ends 604 and 606 of the arm member 602 are aligned with thecounterbores 622 on the respective power end housing 12 and the gearbox600. The shoulder bolts 618 are then inserted through ball joints 610 onrespective ends 604 and 606 and then into the counterbores 622. Eachshoulder bolt 618 is tightened within the counterbores 622 to preventseparation of the shoulder bolts 618 from the counterbores 622.

Alternatively, either end 604 or 606 is first secured to either thepower end housing 12 or the gearbox 600 as previously described. Oncesecured thereto, the unsecured or free end 604 or 606 is pivoted via theball joint 610 so that the ball joint 610 on the unsecured end of thearm member 602 is otherwise aligned with the counterbore 622 on thepower end housing 12 or the gearbox 600, whichever is unattached to thearm member 602. Once aligned, a shoulder bolt 618 is used to secure thesecond end 604 or 606 to the corresponding counterbore 622. If, however,prior to securing the second end 604 or 604, the ball joint 610 cannotbe aligned with the counterbore 622, the length of the arm member 602 isadjusted, as previously discussed, so that the ball joint 610 alignswith the counterbore 622 to enable the shoulder bolt 618 to secure thearm member 602 thereto.

It should be understood that while the arm members 602 are securedbetween the gearbox 600 and the power end housing 12, the arm members602 may be otherwise utilized. For example, referring to FIG. 55, onearm member 602 is secured between the power end housing 12 and a secondarm 602 is secured between the gearbox 600 and either a skid or atrailer 660. Alternatively, the arm members 602 may both extend from thegearbox 600 and the power end housing 12 directly to the skid and/ortrailer 660.

Referring now to FIGS. 56 and 57, the power end housing 12 is supportedon a skid 500. Referring specifically to FIG. 56, the skid 500 includesa base member 502, the base member having a pair of side segments 504and 506, transverse segments 508, 510, and 512 extending between andconnecting the side segments 504 and 506, and feet 514 for supportingthe skid 500 on a support surface. In the embodiment illustrated in FIG.56, the skid 500 includes a plurality of pads 516, 518, 520, 522, 524,526, 528 and 530 that correspond to feet 52 on the frame assembly 40.For example, referring specifically to FIG. 55, pads 520, 522, 524 and526 correspond to and are positioned to align with the feet 52 on themiddle segments 46. Similarly, pads 516, 518, 528 and 530 correspond toand are positioned to align with feet 52 on the end segments 42 and 44.The skid 500 further includes a pair of pads 532 and 534 to support atleast a portion of the fluid end housing 14 (FIG. 1). Referringspecifically to FIG. 57, the side segments 504, 506 and transversesegment 508 each include a plurality of gussets 540 secured thereto toincrease the stiffness of the skid 500 to resist bending and torsionalloading. In FIG. 57, each side segment 504 and 506 include two spacedapart gussets 540 and the transverse segment 508 includes five spacedapart gussets 540, disposed between the pads 518, 520, 522, 524, 526,and 530. It should be understood, however, that a greater or fewernumber of gussets 540 may be utilized on the skid 500 to increase thestiffness thereof.

According to some embodiments, the pads 520, 522, 524 and 526 have athickness that is different from the thickness of pads 516, 518, 528 and530. For example, in the embodiment illustrated in FIG. 56, the pads520, 522, 524 and 526 have a thickness that is less than the thicknessof pads 516, 518, 528 and 530. The varying thickness provides a gapbetween the feet 52 and the pads 520, 522, 524 and 526 to enable theframe assembly 40 to be shimmed in order to reduce “rocking”, vibration,deformation and other unwanted movement.

During manufacture of the frame assembly 40, according to oneembodiment, the feet 52 on segments 42, 44 and 46 are machined so as tolie on the same plane such that when frame assembly is supported on thepads 516, 518, 520, 522, 524, 526, 528 and 530, feet 52 on end segments42 and 44 are in contact with pads 516, 518, 528 and 530 and feet 52 onmiddle segments 46 are aligned with but otherwise spaced apart from pads520, 522, 524 and 526 to provide a gap to receive a shim or other spacerelement. During assembly of the power end housing 12 to the skid 500,the desired shim or other spacer elements can be inserted in the gapsformed between the feet 52 and the pads 520, 522, 524 and 526 to reduceand or otherwise eliminate rocking or other unwanted movement of thepower end housing 12 relative to the skid 500. In other embodiments, thefeet 52 on middle segments 46 are formed to extend onto a differentplane than the plane containing the feet 52 on the end segments 42 and44 and the pads 520, 522, 524 and 526 have a lesser thickness than thepads 516, 518, 528 and 530. In other embodiments, each pad 516-528 isthe same thickness and shims are used to fill any gap between the foot52 and the pads 516-528.

According to other embodiments, the pads have a differing thickness toaccommodate bends in the skid 500. For example, in the event thetransverse segment 508 is bent (i.e. the section 508 of the segment nearthe pad 530 is lower than the section of the segment 508 near pad 518),the pads 518, 520, 522, 524, 526, and/or 530 are machined, as needed,such that a top surface of the pads 518′, 520′, 522′, 524, 526′, and/or530′ rest in the same plane. Accordingly, if the section 508 of thesegment near the pad 530 is lower than the section of the segment 508near pads 518, the thickness of pad 530 will be greater than thethickness of the pad 518, because a greater portion of the pad 518 mustbe removed in order for surfaces 518′ and 530′ to lie in the same plane.

Referring now to FIGS. 58-60, an alternate skid configuration 800 isillustrated. In FIGS. 58 and 59, the skid 800 includes transversesupport members 808, 810 and 812 extending between and connecting theside segments 804 and 806. The transverse support members 810 and 812are formed having a hollow interior and provide additional rigidity andsupport for the areas around the pads 816, 828, 832 and 834. In theembodiment illustrated in FIGS. 58 and 59, for example, the transversesegment 808 is shaped as an I-beam and includes a plurality of verticalgussets 840 disposed on each side of a web member 841; however, itshould be understood that the transverse segment may be shapes otherthan an I-beam shape. The skid 800 further includes a plurality ofvertical gussets 840 disposed on the side segments 804 and 806. In theembodiment illustrated in FIG. 59, the side segments 804 and 806 areformed having a “C” shaped channel in which the gussets 840 are disposedtherein; however, it should be understood that the side segments 804 and806 can be formed other than “C” shaped. Furthermore, the side segments804 and 806 each include a plurality angularly disposed gussets 842disposed within the “C” shaped channel. Gussets 840 and 842 provideadditional support and rigidity to the skid 800.

Referring specifically to FIGS. 58 and 59, the transverse segment 508includes a plurality of gussets 840 disposed around pads 818, 820, 822,824, 826 and 830 and on both sides of the web 841 to provide additionalsupport when the power end housing 12 is secured to the skid 800. In theembodiment illustrated in FIG. 59, the gussets 840 are positioned so asto form a channel 844 to provide access to mounting bolts (notillustrated) to enable tighten mounting bolts to secure the feet 52 tothe skid 800. According to some embodiments, each side segment 804 and806 optionally includes a reinforcing plate 862 secured thereto toprovide additional rigidity to the skid 800. In FIG. 58, for example,the reinforcing plate 862 extends substantially between the transversesupport members 808 and 810. Although the reinforcing plates may extendfor lesser distances and/or be formed of multiple sections.

It should be understood that skids 500 and 800 may be otherwiseconfigured. For example, a greater or fewer number of transversesegments may be utilized. Likewise, additional side segments may bepositioned parallel to side segments 504, 506 and 804, 806. In otherembodiments, additional segments may be angularly disposed between theside segments, the transverse segments or any combinations thereof.

Referring specifically to FIGS. 58-60, the skid 800 further includes aplurality mounting openings 846 disposed on the side segments 804 and806, the openings 846 spaced apart and positioned to enable the skid 800to be secured to a trailer 848 (FIG. 60). In the embodiment illustratedin FIG. 60, the trailer 848 includes a chassis 850 having longitudinalframe segments 852 and 854 and a transverse segment 856 extendingbetween the longitudinal frame segments 852 and 854. The longitudinalsegments 852 and 854 include slots positioned to align with the slots846 on the skid 800 to enable the skid 800 to be secured to the chassis850 via a plurality of bolts or any other suitable attachment means. Asillustrated in FIGS. 58 and 59, the slots 846 are elongated so as toaccommodate differing sized chassis 850 (i.e., the longitudinal framesegments 852 and 854 being spaced farther apart or closer together).Referring to FIG. 60, a bracket 860 is optionally attachable to andcantilevers from the chassis 850 so as to provide additional support tothe skid 800 when the power end housing 12 is secured thereto.

Referring now to FIGS. 61 and 62, the bottom skin 164 is welded to themiddle plate segment 46. In FIGS. 61 and 62, the bottom skin 164 isformed having a generally “J” shaped groove 920 on each edge to bejoined with the corresponding segment 46 (or end plate segment 42 or 44,as applicable) at its weld joint edge near the outer surface. Thesegment 46 has a generally reverse “J” shaped groove 905 and a backingstep 910. The backing step 910 supports the root surface 919 of thebottom skin 164 on a backing surface 915. The backing surface 915transitions to the “J” groove 905 with a mating surface 913, which abutsthe mating end 917 of the bottom skin 164. The mating surface 913prevents lateral movement of the bottom skin 164.

In one embodiment, mating surface 913 has a depth about 0.06 inches andthe backing surface 915 is extended for about 0.13 inches from themating surface 913. The mating end 917 is about 0.06 inches thick andcan thus evenly join the “J” groove 920 with the “J” groove 905, asfurther described below.

The “J” groove 920 of the bottom skin 164 is joined with the “J” groove905 of the segment 46 to form a “U” groove for receiving weld metal toenable formation of a complete penetration weld, without requiring aseparate a backing plate. For example, a molten weld metal 930 isprovided to the “U” groove formed from the two “J” grooves 905 and 920.In one embodiment, the weld metal 930 may be the same or materiallysimilar to the base metal of the segment 46 and the bottom skin 164.

Welding fusion occurs between the weld metal 930, the bottom skin 164and the segment 46 and forms a fused region 935 though the thickness ofthe segment 46, thus unifying the three pieces (i.e., the segment 46,the weld material 930, and the bottom skin 164) into one. For example,the fused region may have a thickness of about 0.06″ to 0.13″, dependingon welding power and material. The solidified weld metal 930 may notnecessarily be planed as illustrated but a proximate plane surface canbe achieved with proper control of the amount of the weld metal 930.Various welding methods may be used, such as flux-cored arc welding, gasmetal arc welding, submerged arc welding, or other appropriate method.In some embodiments, the segment 46, the weld metal 930, and the bottomskin 164 may be submerged in a solution for welding.

It should be understood that the above-mentioned welding process can beused to secure both the top and bottom skin assemblies 162 and 164 tothe end and middle plate segments 42, 44 and/or 46.

The various embodiments and aspects described herein provide multipleadvantages such as, for example, providing a power end housing frameassembly 40 having components that can self-align, enable bearingassemblies to be inserted with minimal risk that the bearing assemblieswill be trapped on the bearing support surfaces, can be more easilyassembled, require less welding, can be manufactured at a reducedweight, and have increased strength thereby operating with lessdeflection and/or deformation to increase the operating life andintegrity of the frame assembly 40 while at the same time reducingmanufacturing costs.

In the foregoing description of certain embodiments, specificterminology has been resorted to for the sake of clarity. However, thedisclosure is not intended to be limited to the specific terms soselected, and it is to be understood that each specific term includesother technical equivalents which operate in a similar manner toaccomplish a similar technical purpose. Terms such as “left” and right”,“front” and “rear”, “above” and “below” and the like are used as wordsof convenience to provide reference points and are not to be construedas limiting terms.

In this specification, the word “comprising” is to be understood in its“open” sense, that is, in the sense of “including”, and thus not limitedto its “closed” sense, that is the sense of “consisting only of”. Acorresponding meaning is to be attributed to the corresponding words“comprise”, “comprised” and “comprises” where they appear.

In addition, the foregoing describes only some embodiments of theinvention(s), and alterations, modifications, additions and/or changescan be made thereto without departing from the scope and spirit of thedisclosed embodiments, the embodiments being illustrative and notrestrictive.

Furthermore, invention(s) have been described in connection with whatare presently considered to be the most practical and preferredembodiments and it is to be understood that the invention is not to belimited to the disclosed embodiments, but on the contrary, is intendedto cover various modifications and equivalent arrangements includedwithin the spirit and scope of the invention(s). Also, the variousembodiments described above may be implemented in conjunction with otherembodiments, e.g., aspects of one embodiment may be combined withaspects of another embodiment to realize yet other embodiments. Further,each independent feature or component of any given assembly mayconstitute an additional embodiment.

What is claimed is:
 1. A drive system for a fluid end of a reciprocatingpump assembly, the drive system comprising: a drive member; a power endhousing having a crankshaft rotatably disposed therein, the power endhousing having an outer wall; a gearbox housing having a gear assemblydisposed therein, the gearbox housing secured to the power end housing,the gear assembly operatively connecting the drive member to thecrankshaft for rotation thereof, the gearbox housing having an outerwall; and at least one stationary arm member extending externallybetween and secured to the respective outer walls of the gearbox housingand the power end housing, the at least one stationary arm memberpositioned to resist relative movement between the gearbox housing andthe power end housing, wherein the at least one stationary arm member isadjustable in length along an axial direction of the at least onestationary arm member; wherein the at least one stationary arm memberincludes a threaded bolt to adjust the axial length of the at least onestationary arm member.
 2. The drive system of claim 1, wherein the atleast one stationary arm member includes at least two stationary armmembers extending between the gearbox housing and the power end housingto resist relative movement between the gearbox housing and the powerend housing.
 3. The drive system of claim 2, wherein the at least twostationary arm members are parallel with respect to each other.
 4. Thedrive system of claim 1, wherein the at least one stationary arm memberincludes at least two stationary arm members extending between thegearbox housing and the power end housing on a same plane.
 5. The drivesystem of claim 1, wherein the at least one stationary arm member ispivotably secured to the power end housing.
 6. The drive system of claim1, wherein the at least one stationary arm member is pivotably securedto the gearbox housing.
 7. The drive system of claim 1, wherein thepower end housing is formed having a front wall, a rear wall, a top walland a bottom wall, the at least one stationary arm member coupled to thepower end housing adjacent the front wall.
 8. The drive system of claim7, wherein the at least one stationary arm member is pivotably securedto the power end housing adjacent the top wall.
 9. The drive system ofclaim 1, wherein the entirety of the at least one stationary arm memberextends between the power end housing outer wall and the gearbox housingouter wall.
 10. The drive system of claim 1, wherein the at least onestationary arm member is secured to the respective outer walls of thegearbox housing and the power end housing via pivotable ball joints atboth ends of the at least one stationary arm member, wherein the atleast one stationary arm member includes a threaded bolt rotatablycoupled with one of the pivotable ball joints.
 11. The drive system ofclaim 10, wherein the at least one stationary arm member furtherincludes a locking mechanism securing an adjusted length.
 12. The drivesystem of claim 11, wherein the at least one stationary arm memberincludes at least one threaded adjustment member for extension in lengthand wherein the locking mechanism includes a nut configured to tightenthe at least one threaded adjustment member and prevent rotation thereoffor securing the adjusted length.
 13. The drive system of claim 1,wherein the at least one arm member includes an elongate body and balljoints movable relative to the elongate body via threaded adjustmentbolts and a lock nut tightenable against the elongate body to preventmovement of the threaded adjustment bolt relative to the elongate body.14. The drive system of claim 13, further comprising threaded adjustmentbolts at respective ends of the elongate body to support the ball jointsthereon, the adjustments bolts extendable from and retractable withinthe elongate body in response to rotation of the elongate body.
 15. Amethod of assembling a drive system for a fluid end of a reciprocatingpump assembly, the method comprises: providing a drive member; providinga power end housing having a crankshaft rotatably disposed therein andhaving an outer wall; securing a gearbox housing having a gear assemblytherein to the power end housing so as to operatively connect the drivemember to the crankshaft for rotation thereof, the gearbox housinghaving an outer wall; and providing at least one stationary arm memberextending externally between and secured to the outer wall of the powerend housing and the outer wall of the gearbox housing to resist relativemovement between the gearbox housing and the power end housing, whereinthe at least one stationary arm member is adjustable in length along anaxial direction of the at least one stationary arm member; adjusting alength of the at least one stationary arm member to extend between thegearbox housing and the power end housing, wherein adjusting the lengthof the at least one stationary arm member includes rotating a threadedbolt of the at least one stationary arm member.
 16. The method of claim15, wherein securing the at last one stationary arm member between thepower end housing and the gearbox housing includes securing at least twostationary arm members between the gearbox housing and the power endhousing.
 17. The method of claim 15, wherein securing the at least onestationary arm member comprises securing at least two stationary armmembers between the gearbox housing and the power end housing in aparallel relationship.
 18. The method of claim 17, further comprisingsecuring the at least two stationary arm members between the gearboxhousing and the power end housing in a same plane.
 19. The method ofclaim 15, further comprising pivotably securing an end of the at leastone stationary arm member to the power end housing.
 20. The method ofclaim 15, further comprising pivotably securing an end of the at leastone stationary arm member to the gearbox housing.
 21. The method ofclaim 15, further comprising securing the at least one stationary armmember adjacent to a front wall of the power end housing.
 22. The methodof claim 21, further comprising securing the at least one stationary armmember adjacent to a top wall of the power end housing.
 23. The methodof claim 15, further comprising securing an end of the at least onestationary arm member to a skid that supports the power end housing. 24.A reciprocating pump assembly comprising: a power end housing having acrankshaft rotatably disposed therein, the power end housing having anouter wall; a fluid end housing; a drive member; a gearbox housinghaving a gear assembly therein, the gearbox housing secured to the powerend housing, the gear assembly operatively connecting the drive memberto the crankshaft for rotation thereof, the gear box housing having anouter wall; a plunger assembly coupled to the crankshaft andreciprocating between the power end housing and the fluid end housing inresponse to rotation of the crankshaft; and at least one stationary armmember extending externally between and secured to the outer wall of thegearbox housing and the outer wall of the power end housing, the atleast one stationary arm member positioned to resist relative movementbetween the gearbox housing and the power end housing, wherein the atleast one stationary arm member is adjustable in length along an axialdirection of the at least one stationary arm member; wherein the atleast one stationary arm member includes a threaded bolt to adjust theaxial length of the at least one stationary arm member.